Multi-function integrated automation cable system and method

ABSTRACT

The present technique relates to the distribution of power and data signals throughout a networked system. For example, three-phase power may be conducted to a device over a set of conductors. One of the conductors, however, may be configured to conduct, in conjunction with a neutral conductor, both one phase of three-phase power as well as data signals in accordance with a predetermined data communications protocol. As an alternate example, the present technique may comprise a set of a first power conductors configured to conduct three-phase power and a secondary power conductor which works in conjunction with an auxiliary conductor to conduct power and data signals. Additionally, the present technique provides for the maintenance data communications and a level of power upon the interruption of three-phase power to a particular component or device.

FIELD OF THE INVENTION

The present technique relates to power and data distribution within anetworked system. More particularly, the present technique relates todistribution of both power and data signals over a power conductor.

BACKGROUND OF THE INVENTION

In a number of applications, networked systems require distribution ofboth power and data signals to and from any number of devices. Forexample, in industrial applications, a networked system may distributepower, typically three-phase power, as well as appropriate data signalsto any number of locations. In traditional systems, power and datasignals are transmitted over discrete wiring pathways. That is, power isdistributed over dedicated power wires and data is distributed overdedicated data wires, both of which are disposed in separate protectiveconduits or cable jackets tubing.

By way of example, networked control for a motor may require three wiresfor the transmission of three-phase power, one or more wires for asecond level of power, an earth ground wire for coupling to ground, aneutral wire for return power signals and a pair of data wires for thecommunication of data signals. Thus, a traditional system may requirenine or more discrete wires for operation. Some systems also use afurther conductor for override or emergency data communication. In turn,this may lead to increased costs with respect to both manufacturing andinstallation. Moreover, the large number of conductors requiredincreases the likelihood of a problem, such as a short, occurring in oneof the wires. This too may increase costs, particularly maintenancecosts.

In more complex systems, power and data signals may be distributed toand from any number of devices, sensors and control circuits all workingin cooperation. Accordingly, the system may be interconnected with trunkcables and branch cables extending from the trunk cables by conductorswhich serve as tapping junctions to the branch cables. However, in manytraditional networks, if an electrically upstream device is brought outof operation, then the electrically downstream devices, althoughfunctioning properly, may also be brought out of operation. This maylead to undesired downtimes where repair perturbs overall operation ofthe entire installation. Thus, it would be advantageous to independentlyinterrupt power to the various components of such systems.

Traditionally, manual disconnects are provided downstream of the trunkcables and connectors for linking branch cables to the trunk cables.Accordingly, a separate device is necessary solely for the selective,more particularly manual, interruption of power to a component. Thisagain may lead to increased costs both in manufacture and installation.

From time to time, problems may occur in certain devices of the networkthat require a total or partial shut down of the device or system.Indeed, operations may be brought to a total or partial halt, forexample, to diagnose and repair the problem in a specific device.Additionally, total or partial system shutdown may occur in response toan override condition of the system in accordance with an overrideprotocol.

During a shutdown, it may be necessary to disengage operating power to aload, such as a motor, for the purposes of repair. Generally, while acomponent is undergoing repair, it may be disengaged from main powerand, as such, becomes divorced from the system. In conventionalnetworked systems, this may also lead to a loss of operating power, andeven data, to the control devices connected to the load, such as relays,protective circuitry, sensing circuitry, actuators, controllers, drives,and so forth. Without these power and data signals, it may be difficultfor a technician to conduct diagnostic analysis of the component orsystem as a whole. This can lead to increased repair and downtimes forboth the system and the component. Accordingly, it would be desirable,during diagnostic tests of the system, to disengage the main power whilemaintaining a second level of power and data signals to and from one ormore disengaged components.

As discussed below, the present technique addresses many of theseconcerns.

SUMMARY OF THE INVENTION

According to one aspect, the present technique comprises a method fortransmitting power and data signals. The method comprises, applyingthree-phase power to a device over a set of power conductors.Additionally, one of the power conductors applies power as well as datasignals to the device in conjunction with a neutral conductor.

According to another aspect, the present technique comprises a cableincluding three conductors configured to conduct three-phase power to adevice. The cable further comprises a fourth conductor configured totransmit data signals to the device in conjunction with one of the powerconductors.

According to yet another aspect, the present technique comprises a cableincluding a set of power conductors configured to conduct three-phasepower to a device. The cable further comprises a secondary powerconductor configured to conduct a secondary power as well as datasignals, the secondary power conductor working in conjunction with anauxiliary conductor.

According to yet another aspect, the present technique comprises asystem for conducting data signals and power throughout a network. Thesystem comprises a data signal source configured to provide data signalsin accordance with a desired data communication protocol and a deviceconfigured to be powered and to receive the data signals. The systemfurther comprises a cable coupled between the data signal source and thedevice, wherein the cable is configured to conduct both data signals andpower to the device.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages and features of the invention willbecome apparent upon reading the following detailed description and uponreference to the drawings in which:

FIG. 1 is a diagram of a portion of an exemplary networked systemincorporating features of the present invention;

FIG. 2 is a schematic of a cable assembly having a plurality ofconductors for the exemplary system of FIG. 1, which conduct power anddata signals to a networked device;

FIG. 3 is an electrical schematic of an alternate embodiment of a cableassembly for conducting power and data signals to a device;

FIG. 4 is a cross-section view of an exemplary cable including aplurality of conductors and having a substantially rectangular profile;

FIG. 5 is a cross-section view of an alternate arrangement for anexemplary cable having a substantially rectangular profile, thealternate arrangement including an unsheathed conductor;

FIG. 6 is an alternate arrangement for an exemplary cable having asubstantially circular profile;

FIG. 7 is a cross-section view of an alternate arrangement for anexemplary cable having a substantially circular profile and including aconductive layer disposed circumferentially about the remainingconductors;

FIG. 8 is a schematic of a power and data transfer assembly having a setof branch conductors respectively coupled to a set of primaryconductors;

FIG. 9 is a schematic of a power and data transfer assembly having a setof internal disconnects;

FIG. 10 is a schematic of a power and data transfer assembly having aplurality of sets of branch conductors respectively connected to asingle set of primary conductors;

FIG. 11 is a schematic of a power and data transfer assembly havingelectrical conductors in a Y-adapter configuration;

FIG. 12 is a schematic of a power and data transfer assembly including aplurality of indicators, such as LEDs electrically in parallel with eachpower conductor and corresponding branch conductors;

FIG. 13 is a schematic of a power and data transfer assembly includingcircuit protection components disposed on the power conductors, as wellas the corresponding branch conductors, the assembly further includingLED indicators;

FIG. 14 is a schematic of a power and data transfer assembly includingdiagnostic circuitry coupled to primary conductors as well as to thebranch conductors;

FIG. 15 is a schematic of a power and data transfer assembly includingnetwork interface circuitry coupled to appropriate branch conductors;

FIG. 16 is a schematic of a power and data transfer assembly includingnetwork interface circuitry coupled to the appropriate power conductors,and a plurality of switches disposed on both the primary conductors andthe branch conductors;

FIG. 17 is a schematic of a power and data transfer assembly comprisingoverride devices disposed on both the primary conductors and the branchconductors, and coupled to network interface circuitry; and

FIG. 18 is a schematic of a power and data transfer assembly including adata port coupled to both the appropriate primary conductors and branchconductors.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

In industrial applications, efficient distribution of power and datasignals is a motivating concern. Referring to FIG. 1, an exemplarysection of a power and data distribution system 10 is presented.Although, for the purposes of explanation, the present embodimentrelates to an industrial application, the present technique can beapplied to any number of settings in which the efficient distribution ofpower and data is a concern. Returning to the present embodiment, thepower and data distribution system 10 comprises a three-phase powersource 12, such as a generator or power grid. The three-phase power maybe ac power, such as 480V power, that powers a load 14. For example, theload 14 may be a motor that operates on three-phase 480Vac power. Forthe present purposes, any voltage or current rating of ac power may beaccommodated. Moreover, the power source 12 may be configured to provideother levels and kinds of power, such as 24Vdc, along with the primarythree-phase power.

To achieve efficient operation, it may be advantageous for the load 14to operate in response to and in cooperation with other systemconditions. That is, the load 14 may be more efficient if operated inlight of, for example, the status or condition of other motors, sensors,controllers, or any other components disposed throughout the system 10.Accordingly, the system 10 facilitates the transmission of data signalsto and from these various components.

In the exemplary system 10, three-phase power and the data signals maybe transmitted and communicated over a plurality of conductors 16. Moreparticularly, three-phase power may be respectively conducted on powerconductors 18. As further discussed below, data signals may betransmitted throughout the system 10 over a neutral conductor 20 and oneof the power conductors 18. To conduct power and data signalsconcurrently over a power conductor, the data signals may be transmittedin accordance with a data communications protocol. Additionally, forprotection of the system 10, as well as to comply with commonly accepteddesign standards, the system 10 may comprise an earth ground conductor22 that provides a path to earth ground. Each of these conductors, asdiscussed further below, may be placed into a single cable therebyproviding a simpler and more compact configuration.

To protect the system 10 against power surges, protection circuitry 24may be disposed electrically downstream of the power source 12 andupstream of all or a large portion of the remainder of the network.However, it is worth note that the protection circuitry 24 may also beplaced electrically proximate to the load or component it protects.Moreover, the protection circuitry 24 may even be integrated into thenetwork component itself. Simply put, the protection circuitry 24 may bedistributed and decentralized with respect to the networked system. Theprotection circuitry 24 may comprise, for example, circuit breakers, aswell as fuses, each designed to prevent inappropriate power levels fromreaching the remainder of the power and data distribution system 10 aswell as the particular network component. Moreover, as discussed indetail below, the protection circuitry 24 may be configured tofacilitate remote triggering and resetting thereof.

Coupled to the conductors 16 and located electrically between the load14 and source 12 may be a controlling device 26, such as a relay, motorcontroller or motor starter. The controlling device 26, in response toan appropriate data signal, may interrupt three-phase power to the load14. As precedingly discussed, a decision to interrupt power to the load14 may be based on monitored conditions of the system 10. Thus, thesystem 10 will typically include a number of sensors and circuitsdisposed throughout the system.

Advantageously, data collected by these circuits or sensors may betransmitted to a central location, such as remote control and monitoringcircuitry 28. Remote control and monitoring circuitry 28 may function asa receiving and processing center for any number of data signals.Additionally, the monitoring circuitry 28 may generate appropriateresponse signals for various components in the system 10. In otherwords, the remote control and monitoring circuitry 28 may act as a nervecenter for the system 10. It should be understood, however, thatcircuitry 28 may include one or more individual controllers, computers,and so forth, in a single or remote locations. Moreover, it should beunderstood that the control circuitry 28 may be distributed throughoutthe system. That is, the control circuitry 28 may be electricallypositioned proximate to the various network components. Indeed, thecontrol circuitry 28 may even be integrated into the network componentsthemselves. In such systems, the network would not necessarily contain a“central control”, but rather an entire collection of remote control andmonitoring circuits 28 working in tandem with one another.

In operation, the remote control and monitoring circuitry 28 may receivedata signals from throughout the power and data distribution system 10.It is worth repeating, however, that the monitoring and controlcircuitry 28 may be distributed and decentralized throughout thenetwork. As further discussed below, these data signals may betransmitted over one of the power conductors 18 and a neutral conductor20 working in cooperation with one another (e.g. via a differentialsignal protocol). Accordingly, the exemplary remote control circuitry 28is coupled to the neutral conductor 20, as well as to the appropriatepower conductor 18. Coupled to the remote control and monitoringcircuitry 28 may be a remote site 30. The remote site 30 may provide alocation for a network administrator or operator to view the signalsreceived by the control and monitoring circuitry 28, determine thestatus of system 10 perform control functions, and so forth. Moreover,the remote site 30 may provide a mechanism through which the operatormay remotely and manually control various individual or sets ofcomponents or operations of the networked system 10.

The remote control and monitoring circuitry 28 may, for example, receivedata signals from sensors or actuators 32 disposed throughout the system10. To operate, the sensors and actuators 32, and the various networkeddevices 26 may require a level of power different than the exemplary480V ac power. For example, the sensors and actuators 32 may require alevel of power such as 110V single phase ac or 24Vdc. Accordingly, powersupply circuitry 34 may be disposed electrically between the powersource 12 and the sensors and actuators 32. Advantageously, theexemplary power supply circuitry 34 is coupled to a power conductor 18,the neutral conductor 20 and the earth ground conductor 22. Thus, thepower supply circuitry may receive a single phase of the three-phasepower and appropriately convert this power to an operable power level.Moreover, the power supply circuitry may receive operating power fromthe power conductor 18. By way of example, the power supply circuitry 34may rectify the 110V single phase ac power to a 24Vdc power.Additionally, the power supply circuitry 34 may be coupled to the groundconductor 22 so as to provide the power supply circuitry with a path toearth ground.

With appropriate power, the sensors and actuators 32 may receive andtransmit data signals throughout the system 10. By way of example, thesensor may comprise a sensor indicative of the status or position of amachine component or workpiece. That is, the sensor 32 may be configuredto indicate whether the component or workpiece is in an appropriateposition to permit a programmer or manually controlled operation toproceed. Additionally, again by way of example, actuators may compriseany suitable devices, such as switches, relays, motors, control valves,pumps, hydraulic or pneumatic cylinders and so forth.

The data obtained by the sensors 32 or indicative of the condition ofthe actuators 32 may not be in a form that is interpretable by theremote control and monitoring circuitry 28. Accordingly, networkinterface circuitry 36 translates these signals into data signals thatare more appropriate. That is, the network interface may translate theraw data into data signals in accordance with the predetermined datacommunications protocol. Such protocols may include standard protocolsknown in the art, such as DeviceNet protocol, ControlNet protocol,ProfiBus protocol, and so forth. Additionally, the network interfacecircuitry 36 may translate return data signals from the remote controland monitoring circuitry 28 to the sensors or actuators 32. Again totransmit the data signals, the network interface is electrically coupledto the appropriate power conductor, that is the power conductor 18 alsocarrying data signals, as well as the neutral conductor 20. Inoperation, the interface circuitry 36 translates the received datasignals and sends response signals which, in turn, instruct an actuatorin its function.

Once these signals from the sensors and actuators 32 are received by theremote control and monitoring circuitry 28, they may be interpreted soas to determine the appropriate response signals for the controllingdevice 26, thereby controlling the load 14. The remote control andmonitoring circuitry 28 may conduct, over the conductors 16, theappropriate data signals throughout the system 10. Coupled to theconductors 16, may be a power and data transfer assembly 40 which tapsoff of the conductors 16 and conducts the appropriate power and datasignals to the controlling device 26 and, in turn, to the load 14. Inthe illustrated embodiment, a set of branch power conductors 42 conductthree-phase power through the power and data transfer assembly 40 andinto controlling device 26. Coupled to these branch conductors may be adisconnect 44 configured to interrupt at least one phase of thethree-phase power prior to the power reaching the controlling device 26,as described below. Advantageously, the disconnect facilitates powerinterruption to the load 14 upstream of the device 26, thereby allowing,if desired, one phase of power to reach the controlling device 26 orload 14. Additionally, the power and data transfer assembly 40 conductsnetwork data signals to the controlling device 26, thereby controllingthe load 14. That is, the transfer assembly 40 may receive data signalsand, in turn, produce a signal which trips the controlling device 26,thereby interrupting power to the load 14.

Also, within the power and data transfer assembly 40 may be varioustypes of auxiliary circuitry 46. The auxiliary circuitry may beconfigured to transmit signals indicative of the condition of thecontrolling device 26. For example, the auxiliary circuitry may producea response signal if a relay is tripped, thereby confirming loss ofpower to the load 14. However, the auxiliary circuitry 46 may provideany number of functions to the power and data transfer assembly 40 aswell as to the system 10. Indeed, the auxiliary circuitry 46 may beemployed to present a secondary signal indicative of the status of anynumber of system conditions.

The auxiliary circuitry 46 may operate from power other than thatprovided by the main (e.g. 480V) ac three-phase power. Accordingly,power supply circuitry 34 may be employed to alter the power signal fromthe power conductors to a level more appropriate for the auxiliarycircuitry 46. As discussed above, power supply circuitry 34 may becoupled to one of the power conductors, the neutral conductor 20, and anearth ground 22. The power supply circuitry 34 receives one phase of thethree-phase power and converts this power to a power level moreappropriate to the auxiliary circuitry 46. Again, by way of example, thepower supply circuitry 34 may rectify and convert single phase 110V acpower to 24Vdc power. Once appropriately conditioned or converted, thepower supply circuitry provides sufficient power to the auxiliarycircuitry 46 for operation. Additionally, the auxiliary circuitry 46 maythen transmit this conditioned power, if appropriate, to the controllingdevice 26 for operation. However, if the controlling device 26 requiresa power level different than that of the auxiliary circuitry 46, thenthe power supply circuitry 34 may be directly coupled to the controllingdevice 26 to provide an appropriate power level.

Similar to the sensors and actuators 32, the auxiliary circuitry 46 maynot provide data signals interpretable by the remote control andmonitoring circuitry 28 and vice-versa. Accordingly, network interfacecircuitry 36 may also be provided within the power and data transferassembly 40. As discussed above, the network interface circuitryreceives data signals from the auxiliary circuitry 46 and translates thesignals into data signals comprehendible by the remote control andmonitoring circuitry 28, that is, data signals in accordance with thedata communications protocol in use. To conduct these appropriatelytranslated data signals to the remote control and monitoring circuitry,the network interface circuitry 36 is coupled to the appropriate powerconductor (i.e., the power conductor conducting both data and power) anda neutral conductor 20. It is again worth nothing that the remotecontrol and monitoring circuitry 28 may be distributed throughout thenetwork and may also be electrically proximate to the respective networkcomponents. Additionally, the network interface may receive data signalsfrom the remote control and monitoring circuitry and translate suchsignals into signals appropriately understandable by the auxiliarycircuitry 46. In turn, the auxiliary circuitry may transmit thetranslated signals to the controlling device 26, thereby actuating thecontrolling device 26 and interrupting power to the load 14. It is worthnote, however, that the network interface, if so desired, may bypass theauxiliary circuitry 46 and couple directly to the controlling device 26.Indeed, if so desired, the controlling device may bypass the assembly 40and be directly coupled to the conductors 16.

In many instances, it may be necessary to interrupt power to the load inresponse to an override condition occurring in the system 10.Accordingly, the system 10 may include override control circuitry 48.The override circuitry 48 receives data signals from the network anddetermines, in accordance with an override protocol, whether an overridesignal is to be transmitted. If so, then the override circuitry producesthis signal in accordance with both the override protocol as well as thedata communications protocol, thereby interrupting power to the load 14.The override circuitry 48 may be centralized in a central controlconfiguration or distributed throughout the system. For example,override circuitry 48 may be integrated into the components of thenetwork. Indeed, the override circuitry 48 may be integrated into agiven network component and configured to terminate power to thecomponent in response to a detected override condition within thecomponent. Simply put, the component may terminate power to itself.Moreover, the override circuitry 48 within a component may be capable ofsending a signal that terminates operation and power to the entiresystem. Depending on the nature and origin of the interrupt command, anynumber of override protocols may be executed.

For the purposes of explanation, the networked system or power and datadistribution system 10 may implement a simple press operation. In thisexplanatory example, the load 14 may be viewed as a motor configured todrive a press plunger in a reciprocating manner. The exemplary press,more particularly the motor of the press, may be powered by three-phase480Vac power. Coupled between the power source and the press motor maybe a controlling device 26, such as a motor controller or contactor.When open, the contactor would prevent three-phase power from reachingthe motor, thereby disabling the press. However, the contactor mayoperate based upon logic to determine when and for how long power to themotor should or should not be applied. Accordingly, the various sensors32 throughout the system may provide data, once translated by networkinterface circuitry 36, to the remote control and monitoring circuitry28 which, in turn, analyzes this data and produces a return data signalindicative of what the desired contractor status should be. This signalmay then be transmitted over the appropriate power conductor 18 (i.e.,the conductor that conducts both the data signals and one phase of theac power) and the neutral 20 to the power and data transfer assembly 40.

Once received by the assembly 40, the network interface circuitry 36disposed therein translates this signal to one which is moreappropriately understood by either the auxiliary circuitry 46 or thecontrolling device 26. This signal would then instruct the controllingdevice (i.e., the contactor) to either maintain power to the motor or tointerrupt power in response to a system condition.

Additionally, and continuing the example, the override circuitry 48 mayproduce response signals so as to prevent the motor (i.e., load 14) fromoperating because of a certain condition of the system 10. By way ofexample, a sensor 32 may be coupled to a press door or guard andconfigured to indicate whether this guard is either in an opened orclosed position. The sensor 32 would then be scanned periodically, or,alternatively, when the door is open, the sensor would then transmit anindicative signal to the network interface which would in turn translatethe signal to one appropriate for the remote control and monitoringcircuitry 28. If the signal is related to an override event, the signalis transmitted to override control circuitry 48 or to both thatcircuitry and the remote control monitoring circuitry 28. The overridecircuitry interprets the signals and determines, in accordance with anoverride protocol, that the press guard is open and, as such, the motorshould not be operable. The override circuitry would then create a datasignal, in accordance with a predetermined override protocol, andtransmit this newly created data signal, over the appropriateconductors, to the power and data transfer assembly 40. Once received,the power and data transfer assembly, by way of the network interfacecircuitry 36, appropriately instructs the controlling device to trip thecontactor open and, as such, prevent operation of the motor until thesensor indicates that the door is closed. Advantageously, the overridecircuitry 48 thus functions in parallel with the control circuitry, andtransmits coordinated signals in its own protocol over the sameconductors.

Turning next to FIG. 2, the exemplary network preferably utilizes acable assembly grouping the conductors 16 for coupling to the controldevice 26. Although the exemplary network relates to conductors 16coupled to a control device 26, which in turn is coupled to a load 14,the conductors 16 may be configured to be coupled to any number ofelectronic components. Simply put, the conductors 16 may be configuredto provide data signals as well as power to any number of networkedcomponents or devices within the system. Moreover, it should be notedthat any number of network components may be electrically disposedbetween the conductors 16 and the device 26. However, for the purpose ofexplanation, these components are not illustrated. Returning to theexemplary portion of the network, the conductors 16 comprise three powerconductors 18 a, 18 b, and 18 c each conducting a phase of three-phasepower. Additionally, as discussed above, the conductors 16 include aneutral conductor 20 and a ground conductor 22 coupled to earth ground.Advantageously, conductors 18 a and 18 b may include disconnects 44configured to selectively interrupt the phases of power carried by theseconductors.

To operate, the device 26 may be coupled to each of the power conductors18 a, 18 b and 18 c, and thereby receive three-phase power.Additionally, data signals 50 may be communicated to and from the deviceover an appropriate conductor (i.e., the power conductor carrying bothpower and data signals) 18 c and the neutral conductor 20 working inconjunction with one another. Advantageously, the communication signalsor data signals 50 may be in accordance with the data communicationsprotocol that facilitates the transmission of power and dataconcurrently over a power conductor. For example, the datacommunications protocol may comprise a standard protocol adapted toprovided data signals over power, such as a protocol known as HomePlug,or similar technologies. Upon interruption of power conductors 18 a and18 b via disconnects 44, power conductor 18 c, working in conjunctionwith neutral conductor 20, continues to provide at least one phase of acpower to the device 26, as well as data signals as indicated generallyat reference numeral 50. The use of the power conductor 18 c and neutralconductor 20 is particularly preferred where the communications protocolrelies upon differential communication. Accordingly, the device 26 mayremain operable in, for example, a diagnostic state (i.e., allow thedevice to maintain data communications with the remainder of the system10 while disconnects 44 are open). Advantageously, such communicationsmay facilitate the repair and/or maintenance of a device even when thedevice 26 is no longer fully operational (i.e. cannot power the load).That is, the device 26 may include: a fully operational mode, whereinall appropriate power and data signals are communicated to the device; amaintenance mode, wherein power signals may be partially interrupted butdata signals are maintained; and a service mode, wherein all powersignals are disconnected.

The conductor assembly of FIG. 2 illustrates that, in conjunction with aground conductor for the purposes of circuit protection and compliancewith design standards, three-phase power and data communications signalscan be networked throughout a system 10 over as few as four conductors.In comparison to traditional systems which may require nine or moreconductors for the same purpose, the present technique is significantlymore efficient.

An alternate conductor configuration, as illustrated in FIG. 3, maycomprise six conductors 16 including three primary power conductors 18a, 18 b, and 18 c, a secondary power conductor 52, a neutral conductor20 and a earth ground conductor 22. In this arrangement, similar to theforegoing arrangement, three-phase power is conducted over primary powerconductors 18 a, 18 b and 18 c. Over a secondary power conductor 52, asecond power level, which may be independent of the primary three-phasepower conductors, may also be carried. The second power level may be oneof any number of power levels. For example, the second power may be a24Vdc or a single phase 110Vac. Additionally, the secondary powerconductor may carry the data signals in accordance with thepredetermined data communications protocol as before. Accordingly, whenpower to the primary conductors 18 a, 18 b and 18 c is interrupted bythe disconnects 44, one phase of power and data signals remain over thesecondary power conductor 52. Because the device 26 may be coupled tothe secondary power conductor 52 in conjunction with the auxiliaryconductor 53, the device retains the second power level as well as datacommunications. Indeed, the communication signals or data signals, asindicated at reference numeral 50 may be transmitted between the systemand the device over the secondary power conductor 52 working inconjunction with the auxiliary conductor 53 in accordance with a datacommunications protocol.

Each of these conductors 16 discussed above, as illustrated by FIGS. 4and 5, may be disposed within a single cable 54 having any suitablephysical configuration, such as a substantially rectangular profile. Thecable 54 may comprise a universal jacket 56 within which each of theconductors 18 a, 18 b, 18 c, 20 and 22 are disposed. Advantageously, theuniversal jacket 56 may be configured so as to facilitate open wiring ofthe cable system. That is, the universal jacket may be formed of aninsulative material that is crush resistant. Advantageously, cablingconfigured as such may be run throughout the system without protectiveconduit tubing. Additionally, to further protect each of the individualconductors, the conductors within the cable may also all includeindividual jackets 58 disposed about each of the conductors as shown inFIG. 4. However, in an alternative configuration, as illustrated in FIG.5, the ground conductor 22, or other conductors of the cable, need notbe placed in an individual jacket 58. Because the ground conductor 22does not carry a signal, an individual jacket may not be required.Additionally, in the interests of efficient manufacture and reducingcosts, the remainder of the conductors may also reside intimately incontact with the universal jacket, that is the cable 54 need not includeany individual jackets 58.

The cable 54, as illustrated in FIGS. 6 and 7, may also present acircular profile. In this arrangement, the cable 54 comprises sixconductors: three primary power conductors 18 a, 18 b and 18 c, asecondary power conductor 52 and an auxiliary conductor 53 carrying asecond power level and data signals, and an earth ground conductor 22.Advantageously, the circular profile may facilitate cabling of thesystem 10 in relatively tight and narrow wiring pathways, and facilitatemulti-directional bending where required. As shown in FIG. 7, analternate arrangement of a circular cable 54 comprises a groundconductor layer 22 circumscribed about the individual jackets 58 of thepower conductors 18 a, 18 b and 18 c and the neutral conductor 20.Advantageously, the ground conductor layer 22 may be a metal structurethat provides structural rigidity to the overall cable 54 and canimprove the crush resistance of the cable 54. The ground layer 22 mayalso advantageously provide EMI (Electro-Magnetic Interference)shielding to the remainder of the conductors in the cable 54.

To couple the cabling 54 to a device such as a relay, disconnect, motoror any other load, a power and data transfer assembly 40, as illustratedin FIG. 8, may be employed. The transfer assembly 40 comprises a body 60advantageously formed of corrosion resistant rigid materials, such ashigh density polyethylene (HDPE) or any suitable material or materials,including a variety of plastics. Disposed on the exterior of the body 60may be a set of threaded stems 62 configured to threadingly engagethreaded connectors 64 coupled to the ends of cables 54. Advantageously,the threaded stems 62 and connectors 64 engage corresponding conductorsof the cable 54 and the power and data transfer assembly 40. This may befacilitated by any number of techniques, such as pins and correspondingslots or sockets, well-known to those of ordinary skill in the art.

Within the assembly 40 are the primary conductors, including three-phasepower conductors 66 a, 66 b, and 66 c corresponding to the three-phasepower conductors 18 a, 18 b, and 18 c of the cables 54 discussed above,a neutral conductor 68 corresponding to the neutral conductor 20 of thecable 54, and an earth ground conductor 70 corresponding to earth groundconductor 22 of the cable 54. Once coupled to the appropriate cables 54,the power and data transfer assembly 40 is capable of conductingthree-phase power over the power conductors 66 as well as data signalsover one of the power conductors 66 working in conjunction with theneutral conductor 68.

The transfer assembly 40 may also include a plurality of tap conductorsrespectively coupled to the primary power conductors 66 a, 66 b and 66c, neutral conductor 68 and earth ground conductor 70. Advantageously,the tap conductors 72 provide an electrical pathway for distribution ofthree-phase power and data signals to downstream circuitry, such as asecond device. That is, the transfer assembly 40 may be viewed as a“tee” assembly for interconnecting a plurality of downstream devices toan upstream source or device. In operation, power and data are conductedinto the assembly from an input cable 54 (as exemplified by theleft-most cable input in FIG. 8) through the power and data transferassembly 40 via the primary and tap conductors and out to output cables54 (as illustrated by the lower-most and right-most cable assemblies ofFIG. 8). Thus, the appropriate power and data signals may be receivedfrom a single source and distributed to a plurality of locations ordevices.

By tapping the conductors to the respective devices, the power and datatransfer assembly 40 may include any number of integrated features whichaffect or indicate the status of the branched devices individually. Forexample, the tap conductors carrying two phases of three phase power,(i.e., the tap conductors coupled to power conductors 66 a and 66 b) maycomprise disconnects, such as switches 74. The switches 74 may be anynumber of switch types, such as rotary switches or momentary contactswitches. In the exemplary assembly 40 of FIG. 8, switches 74 facilitateinterruption of two phases of three-phase power to a tap device whilemaintaining all three phases of power to be transmitted to downstreamdevices. That is, the tap device may be partially disengagedindependently of the remaining devices in the system.

Advantageously, the partial interruption of tap conductors 72 maintainsone phase of three-phase power and data signals to the tap device. Inthe exemplary assembly 40, tap conductors 72 that are not disconnectedby such interruption include conductors respectively coupled to thepower conductor carrying both data and power signals (i.e., conductor 66c) as well as to the neutral conductor 68. Thus, the tap device,although not able to power the load, still receives sufficient power forits own operation and retains communication abilities with the remainderof the system.

Additionally, the power and data transfer assembly 40 may include anindicator 76, such as an LED, disposed on any of the conductors,particularly on the interruptible tap conductors. If the switches 74 arein a closed position, then current will flow through the LEDs and intothe secondary device. Accordingly, the LED will be illuminated therebyindicating an active status of a particular tap conductor. However, ifthe switch 74 is in the open position, current will not flow through theappropriate tap conductor and, as such, the LED will be inactive.Moreover, the LED indicators may be configured to provide both andindication of voltage as well as an indication of current. Thus, simplyby viewing the status of the LED, an operator or technician is able todetermine if a switch has been triggered. That is, a technician may beable to visually determine or verify if a given network component orsection is active or “hot”. Clearly, other indicator circuits, logic,and so forth may be envisaged to provide similar visible indication ofthe state of data or power in the conductors. In this and all of theembodiments, additional features, such as lockout mechanisms, may beprovided in assembly do to facilitate servicing. As will be appreciatedby those skilled in the art, such mechanisms generally enable a servicetechnician or electrician to positively prevent physical switching ofthe switches 74 during periods of servicing, as via padlock or similardevice.

Furthermore, by integrating switches and indicators into the power anddata transfer assembly 40, the requirement of additional interconnectedcomponents may be obviated. In other words, additional switchingcomponents or indicators electrically disposed between the power anddata transfer assembly and the downstream cable or device may no longerbe necessary. Advantageously, this reduction in parts can lead to moreconvenient operation, simpler installation, as well as reduction inmaintenance costs.

In certain instances, such as a terminal end of a network, it may beadvantageous to provide a coupling to a single device. As illustrated inFIG. 9, the power and data transfer assembly 40 may present a simplecoupling for input conductors from the system to output conductors for adevice. Moreover, the power and data transfer assembly 40 may includedisconnects, such as switches 74, that disconnect two phases ofthree-phase power to a downstream device while retaining one phase ofthree-phase power and data signals to the device. Advantageously, byemploying the assembly 40, devices downstream of the power and datatransfer assembly may be interrupted from two phases of the three-phasepower while those upstream remain operable.

In yet other instances, it may be advantageous to independentlydistribute power and data signals to a plurality of downstream devicesvia a single assembly 40. Accordingly, FIG. 10 illustrates a power anddata transfer assembly 40 including a plurality of sets of tapconductors 72 a, 72 b and 72 c. Each set of tap conductors may includedisconnects, such as switches 74 a, 74 b, and 74 c, that disconnect twophases of three-phase power to the respective downstream devices. Thus,the power and data transfer assembly 40 allows for independentinterruption of two phases of three-phase power to the respectivedownstream devices. Because the tap conductors may be configured toremain coupled to the power conductor carrying both power and datasignals, that is conductor 66 c, and to the neutral conductor 68, onephase of three-phase power and data signals may still be delivered tothe respective downstream devices. Advantageously, the devices mayremain networked to the system even though two phases three-phase powerhave been disconnected therefrom.

Turning next to FIG. 11, in this arrangement, the power conductors 66 a,66 b and 66 c are arranged with the tap conductors 72 in a Y-patternwith the primary conductors. Advantageously, the Y-pattern assembly mayfacilitate tapping of the power and data signals to better match thespatial configuration of downstream devices and to accommodate variousnetwork topologies. Again, similar to the above arrangement, the primaryconductors 66 a and 66 b, as well as the respectively coupled tapconductors, may include switches that interrupt two phases ofthree-phase power to the appropriate downstream device. Again, loadpower may be independently interrupted to the downstream devices whilemaintaining operational power and data communication to these devices.

The power and data transfer assembly 40 may also be arranged to provideindications of whether problems, such as shorts circuits, exist upstreamor downstream of the transfer assembly 40. Accordingly, the power anddata transfer assembly 40 may include indicators disposed at appropriatelocations on the power conductors 68 a, 68 b and 68 c as well as on thecorresponding tap conductor 72. As exemplified in FIG. 12, a set of LEDindicators 76 may be coupled to each of the three-phase power conductors66 a, 66 b, and 66 c, both upstream of the tap conductor 72 as well asdownstream of the tap conductors 72. In operation, in the event a powerconductor 66 a, 66 b or 66 c is damaged upstream of the power and datatransfer assembly, all of the LED indicators coupled to the appropriatepower conductor 66 a, 66 b or 66 c, would show an inactive status. Incontrast, should a problem occur downstream of assembly 40, and not inthe tap device, the appropriate indicator 76 upstream of the tapconductors and on the tap conductors will show an active status, whereasthe indicator downstream of the tap conductors will show an inactivestatus. Thus, an operator could easily determine that repairs must beconducted downstream of the appropriate assembly, advantageouslyreducing the time necessary to detect and address the problem.

Should problems similarly occur in the tap device the indicators on theappropriate conductors upstream and downstream of the tap conductorswill indicate an active status, whereas the indicator on the respectivetap conductors will show an inactive status. Again, by viewing thisintegrated indicator, the operator or repair technician would be easilyable to determine along which path the problem has occurred. Again,advantageously, this may lead to reduced repair times and increasedefficiencies.

The power and data transfer assembly may also include integrated circuitprotection components, such as fuses 78 or circuit breakers 80 asillustrated in FIG. 13. If, for example, an inappropriate power levelwas conducted over any of the power conductors 66 a, 66 b or 66 c, theappropriate fuse 78 or circuit breaker 80 would be triggered. Moreover,the protection components 78 and 80 may be configured to operateremotely in response to the appropriate data signals. That is, they maybe configured to be triggered or reset in response to certain datasignals transmitted over the appropriate conductors. Advantageously,indicators 76 may be coupled to the appropriate power conductors 66downstream of the circuit protection components 78 or 80. Accordingly,if a fuse 78 or circuit breaker 80 is tripped, the indicator will soindicate, and as such tell the operator which fuse or circuit breakerhas been tripped. In response, the maintenance technician or operatormay simply replace the tripped fuse 78 or switch the circuit breakerback into a conducting position, or otherwise service the system.Indeed, the fuses 78 are adapted for easy separation from the remainderof the assembly 40. That is, the protection components 78 and 80 may bereplaced without removal or disconnection of the remainder of thetransfer assembly 40 from the network.

Another feature which may be integrated into the power and data transferassembly is diagnostic circuitry 82. As illustrated in FIG. 14, thediagnostic circuitry may be coupled to all of the conductors within thepower and data transfer assembly 40. Additionally, the diagnosticcircuitry 82 may be configured so as to receive and transmit datasignals over the appropriate power conductor 66 c and neutral conductor68 in accordance with the predetermined data communications protocol.Advantageously, the diagnostic circuitry may interpret both the datasignals as well as the conditions of the power conductors and, with suchinformation, determine where a problem or error may be occurring. Inresponse, the diagnostic circuitry may then send a data signal to theappropriate network component, such as the controller 26 for display ata remote site (see FIG. 1). To facilitate computation and analysis ofthe various signals and power conditions, diagnostic circuitry maycomprise a microprocessor, or any other suitable data processing and/orlogic device. Moreover, the diagnostic circuitry may comprise amechanism that facilitates verification of the connectivity of thetransfer assembly 40 as well as the components to which it is coupled.For example, the diagnostic circuitry may comprise a mechanism forproducing a test voltage and test current. The diagnostic circuitry mayanalyze the network system's response to the applied test voltage andcurrent and, in turn, develop a diagnosis.

In many instances, a device coupled downstream of the power and datatransfer assembly may not contain circuitry capable of receiving orsending data signals in accordance with the predetermined datacommunications protocol. Accordingly, as illustrated in FIG. 15, thepower and data transfer assembly may include network interface circuitry36 disposed therein. Advantageously, the network interface circuitry 36,as discussed above, receives data signals in accordance with the datacommunications protocol over the appropriate power conductor 66 c andthe neutral 68 and subsequently translates these signals for receipt bythe downstream device. Moreover, the network interface circuitry 36 mayreceive signals from a downstream device and, in turn, translate thesignals for distribution to the remainder of the system, again over theappropriate power conductor 66 c and neutral conductor 68.Advantageously, by integrating this circuitry into the transfer assembly40, additional components coupled between the assembly and the cable ordownstream device are no longer necessary, thereby reducingmanufacturing and installation costs.

Additionally, the network interface circuitry 36 may be coupleddownstream of switches 74 as illustrated in FIG. 16. As such, thenetwork interface circuitry 36 may be configured so as to interpret thestatus of the switches, i.e., open or closed, and translate this datainto signals more appropriately transmittable in accordance with thepredetermined data communications protocol.

Not only may it be advantageous to note the condition of a switch, italso may be advantageous to control power transmission to devicesdownstream of the transfer assembly 40. Accordingly, the power and datatransfer assembly may comprise override devices that are capable ofinterrupting any one or all of the three phases of power in response toan appropriate override protocol. As illustrated in FIG. 17, overridedevices 84 may be disposed within the power and data transfer assemblyon the power conductors 66 both upstream and downstream of the tapconnectors as well as on the respective tap power conductors.Additionally, the override devices 84 may be coupled to networkinterface circuitry 36.

In operation, override circuitry 48 (see FIG. 1) may determine, inresponse to an override protocol, that power to a specific device is tobe interrupted. In turn, the override circuitry transmits a data signalover the power conductor 66 c and neutral conductor 68 to networkinterface circuitry 36 disposed within the power and data transferassembly 40. The network interface translates the signals into signalsmore appropriately understandable by the respective override devices.The signals may be such that they instruct the override device 84 tointerrupt power to the appropriate downstream devices. As presented inthe earlier example, an open press guard within the system may cause theoverride circuitry 48 to send a signal to the override device 84 todisengage power to the corresponding press motor.

Additionally, at many points during operation, it may be advantageousfor a technician or operator to be able to determine what data signalsare being transmitted through the power and data transfer assembly 40.Accordingly, the assembly 40 may comprise a data port 86. By couplingthe data port 86 to the appropriate power conductor 66 c and neutralconductor 68, a technician may be able to interface a remote device (notshown), such as a laptop computer or other interface module, to thepower and data transfer assembly. The port then facilitates transmissionof the data signals being conducted within the power and data transferassembly to the interface module. Moreover, the transmission of data mayalso be conducted in accordance with a wireless protocol. Indeed, theport 86 may comprise a radio frequency (rf) transmitter or a transmittercompatible with an IEEE 802.11(b) or other wireless standard. Theseprotocols may wirelessly communicate data with the exemplary laptop.Advantageously, the technician, via the interface module, may also beable to input data signals to the system 10 (see FIG. 1) via a port 86.

While the invention may be susceptible to various modifications andalternative forms, specific embodiments have been shown in the drawingsand have been described in detail herein by way of example only.However, it should be understood that the invention is not intended tobe limited to the particular forms disclosed. Indeed, one or more of thedisconnects 44 or 74 may be multi-position or multiple positiondisconnects for interrupting two power conductors (e.g., a maintenanceposition), three power conductors (e.g., a service position), or fordisconnecting one device or a series of devices. Additionally, the LED'smay aid in indicating that no power is present, to permit the readyservicing of the devices without donning special gear or clothing.Clearly, the invention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the invention asdefined by the following appended claims.

1. A power and data distribution system, comprising: a data signalsource configured to provide data signals in accordance with a desireddata communications protocol; a device powered by at least one phase ofthree-phase power and configured to receive data signals; and a cableelectrically coupled between the data signal source and the device, thecable comprising: first and second power conductors configured toconduct two phases of three-phase power, and a third conductorconfigured to carry a third phase of three-phase power and data signalsfrom the data signal source; and a neutral conductor configured toreturn power and to carry data signals from the data signal source incooperation with the third conductor; wherein the cable is configured tofacilitate transmission of both data signals and the third phase ofpower to the device via the third and neutral conductors uponinterruption of power to the first and second conductors.
 2. The systemas recited in claim 1, further comprising a switch configured tointerrupt the first and second power conductors.
 3. The system asrecited in claim 1, further comprising power supply circuitry configuredto convert the third phase of power to a second power level.
 4. Thesystem as recited in claim 3, wherein the second power level comprises adirect current.
 5. The system as recited in claim 1, further comprisingoverride circuitry configured to produce data signals in accordance withan override protocol in addition to the data communications protocol. 6.The system as recited in claim 1, further comprising remote controlcircuitry configured to selectably interrupt the first and second powerconductors.
 7. A power and data distribution system, comprising: a datasignal source configured to provide data signals in accordance with adesired data communications protocol; a device powered by at least onephase of three-phase power and configured to receive data signals fromthe data signal source; and a cable electrically coupled between thedata signal source and the device, the cable comprising: a plurality ofprimary power conductors configured to carry three-phase power;secondary power conductors configured to conduct power and data signalsfrom the data signal source to the device; wherein the cable isconfigured to maintain the data signals and power to the device via thesecondary power conductors upon interruption of power to the pluralityof primary power conductors.
 8. The power and data distribution systemas recited in claim 7, wherein one of the secondary power conductorscomprises a neutral conductor.
 9. The system as recited in claim 7,further comprising override circuitry, the override circuitry configuredto produce signals in accordance with an override protocol in additionto the data transmission protocol.
 10. The claim as recited in claim 7,further comprising power supply circuitry adapted to convert at leastone phase of three-phase power to a control power.
 11. The claim asrecited in claim 10, wherein the control power comprises a directcurrent.